Centralized, time-shared vapor sterilization system

ABSTRACT

A system for conveying a sterilant vapor to a plurality of processing lines having articles moving therealong. The system includes a central source of a sterilant vapor. A conveying device is provided for conveying a sterilant vapor from the central source to a plurality of processing lines. A plurality of sensing devices are provided for sensing a plurality of operational parameters associated with the system and the plurality of processing lines. A controller is provided for receiving signals from the plurality of sensing devices. The controller is programmed to monitor continuously the plurality of sensing devices to determine if an event indicative of a malfunction has occurred with respect to the system or the plurality of processing lines. The controller is programmed to adjust the operation of the system in response to the event to maintain uninterrupted operation of one or more of the plurality of processing lines.

RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/418,015, filed Nov. 30, 2010, which is fully incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates generally to the sterilization ofarticles, and more particularly, to a system for supplying a vaporsterilant from a central source to a plurality of processing lineshaving articles moving therealong and a method of operating the same.

BACKGROUND OF THE INVENTION

In the food industry, facilities for packaging products, such as food,beverages, and the like, are known to include a plurality of processinglines therein. The processing lines are designed to place the productinto an article, such as a container. The containers typically aresterilized prior to being filled with a desired product.

Some filling lines use containers that are made from a flat sheet of webmaterial. The web material typically is made from layers of papercardboard, plastic and foil that are laminated together. Prior toforming the web material into a container, the web material is dippedinto a bath of liquid hydrogen peroxide, dried and formed into thecontainer. Dipping the containers into a high concentrate of liquidhydrogen peroxide (typically at 35% concentration) may result in highresidual levels of hydrogen peroxide in the material.

Other processing lines use containers that have a closed end and an openend. The open end of each container is oriented upward to allow liquidperoxide to be sprayed into the container. The container is then rinsedwith sterile water. To drain the container, the container is inverted sothat the open end of the container is oriented downward. The containeris then inverted again so that the open end of the container is thenoriented upward to allow for filling with a beverage.

It is desirable to sterilize the containers in a manner that does notrequire repeated re-orienting of the containers and that reduces theamount of residual peroxide on the container. By simplifying thesterilization of the containers and reducing the amount of residualperoxide on the containers, the time required to sterilize thecontainers can be reduced.

Recently, the food industry has begun to use hydrogen peroxide vapor tosterilize containers. Hydrogen peroxide vapor has proven to be efficientat sterilizing the containers quickly and at leaving small amounts ofresidual peroxide on the containers. Some systems provide the hydrogenperoxide vapor from a central source to the plurality of processinglines to sterilize the containers moving therealong. In these systems,the hydrogen peroxide vapor is typically conveyed from the centralsource simultaneously to each processing line at the same concentrationand at the same flow rate.

One problem with a central source of hydrogen peroxide vapor arises whena malfunction occurs along one processing line. A malfunction along oneprocessing line will cause all the processing lines to be shut downuntil the malfunction is repaired. As can be appreciated, if all theprocessing lines in the facility are shut down, the output of thefacility is reduced and the operating cost of the facility increases. Itis therefore desirable to have a system and method for providing asterilant vapor to one or more processing lines when an event indicativeof a malfunction is detected with the system or one or more of theplurality of processing lines.

The present invention provides a system for providing a sterliant vaporto a plurality of processing lines having articles moving therealong.The system includes a plurality of sensors associated with the pluralityof processing lines which sensors provide signals indicative of theoperation of the system and the plurality of processing lines. Acontroller is provided for monitoring continuously the plurality ofsensors. The controller is programmed to monitor the plurality ofsensors to detect an event (or events) that is indicative of amalfunction with the system or with one or more of the plurality ofprocessing lines. If an event is detected, the controller adjusts theoperation of the system and/or the plurality of processing lines toprovide uninterrupted operation of one or more of the plurality ofprocessing lines.

SUMMARY OF THE INVENTION

In accordance with a preferred embodiment of the present invention,there is provided a system for conveying a sterilant vapor to aplurality of processing lines having articles moving therealong. Thesystem includes a central source of a sterilant vapor. A conveyingdevice is provided for conveying a sterilant vapor from the centralsource to a plurality of processing lines. A plurality of sensingdevices are provided for sensing a plurality of operational parametersassociated with the system and the plurality of processing lines. Acontroller is provided for receiving signals from the plurality ofsensing devices. The controller is programmed to monitor continuouslythe plurality of sensing devices to determine if an event indicative ofa malfunction has occurred with respect to the system or the pluralityof processing lines. The controller is programmed to adjust theoperation of the system in response to the event to maintainuninterrupted operation of one or more of the plurality of processinglines.

An advantage of the present invention is a system for providing asterilant vapor to a plurality of processing lines from a central sourceof a sterilant vapor.

Another advantage of the present invention is a system, as describedabove, that includes a plurality of sensors that continuously monitorthe operation of the plurality of processing lines.

Yet another advantage of the present invention is a system, as describedabove, wherein a controller is programmed to detect an event indicativeof a malfunction with the system or one or more of the plurality ofprocessing lines.

Another advantage of the present invention is a system, as describedabove, wherein the controller adjusts operation of the system inresponse to a detected event to provide uninterrupted supply of thesterilant vapor to one or more of the plurality of processing lines.

Yet another advantage of the present invention is a system, as describedabove, wherein the controller adjusts the output of the central sourcein response to an event (or events) indicative of a malfunction with thesystem or one or more of the plurality of processing lines.

Still another advantage of the present invention is a system, asdescribed above, wherein the controller adjusts the concentration ofsterilant vapor from the central source in response to an event (orevents) indicative of a malfunction with the system or one or more ofthe plurality of processing lines.

Another advantage of the present invention is a system, as describedabove, wherein the controller adjusts the flow rate of sterilant vaporfrom the central source in response to an event (or events) indicativeof a malfunction with the system or one or more of the plurality ofprocessing lines.

Still another advantage of the present invention is a system, asdescribed above, wherein the controller adjusts the temperature of thesterilant vapor from the central source in response to an event (orevents) indicative of a malfunction with the system or one or more ofthe plurality of processing lines.

Yet another advantage of the present invention is a system, as describedabove, wherein the controller adjusts the speed of one or more of theplurality of processing lines in response to an event (or events)indicative of a malfunction with the system or one or more of theplurality of processing lines.

These and other advantages will become apparent from the followingdescription of a preferred embodiment taken together with theaccompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangement ofparts, a preferred embodiment of which will be described in detail inthe specification and illustrated in the accompanying drawings whichform a part hereof, and wherein:

FIG. 1 is a drawing schematically illustrating a sterilant supply systemfor supplying a vapor sterilant to a plurality of processing lines,illustrating a preferred embodiment of the present invention;

FIG. 2 is a drawing pictorially illustrating a vaporizer unit of thesterilant supply system shown in FIG. 1; and

FIG. 3 is a drawing schematically illustrating an aeration unit of thesterilant supply system shown in FIG. 1.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

Referring now to the drawings wherein the showings are for the purposeof illustrating a preferred embodiment of the invention only, and notfor the purpose of limiting the same, FIG. 1 shows a sterilant supplysystem 10 for providing a sterilant vapor to a plurality of processinglines having containers 12 moving therealong. Sterilant supply system 10will be described with respect to sterilizing containers moving along aplurality of processing lines in a food packaging facility. However, itis appreciated that the present invention may find advantageousapplication in other systems for supplying a sterilant vapor to aplurality of processing lines having articles, such as medicalinstruments, moving therealong.

In the embodiments shown, conveyors 14A, 14B represent two (2)processing lines associated with system 10. Conveyor 14A represents aportion of a first processing line for containers 12. Conveyor 14Brepresents a portion of a second processing line for containers 12. Afirst motor 16A is provided for causing conveyor 14A to move containers12 therealong. A second motor 16B is provided for causing conveyor 14Bto move containers 12 therealong.

Conveyors 14A, 14B extend through decontamination chambers 50A, 50B.System 10 conveys the sterilant vapor to the portion of conveyors 14A,14B that is disposed within decontamination chambers 50A, 50B. Each ofdecontamination chambers 50A, 50B has an enclosure or housing 52.Housing 52 defines a space or region 54 through which containers 12 tobe sterilized are conveyed by conveyors 14A, 14B. After containers 12are sterilized by system 10, containers 12 are conveyed to a fillingstation (not shown), wherein containers 12 are filled with a beverage orsome other product.

Broadly stated, sterilant supply system 10, according to the presentinvention, is comprised of a sterilant supply unit, an air conditioningunit, a vaporizer unit, a destroyer unit and an aeration unit. Theforegoing components are described in detail in U.S. patent applicationSer. No. 11/741,299, hereby incorporated by reference. In the embodimentshown, sterilant supply system 10 includes a single sterilant supplyunit 100, a single air conditioning unit 200, a single vaporizer unit300, a single destroyer unit 600 and a single aeration unit 700. It iscontemplated that sterilant supply system 10 may convey a sterilantvapor to more than two (2) processing lines. However, sterilant supplysystem 10 will be described below in reference to conveying a sterilantvapor to two (2) processing lines in order to simplify the descriptionof the present invention.

Referring now to FIG. 1, sterilant supply unit 100 is shown. A supplyline 112 connects sterilant supply unit 100 to an external supply 114 ofliquid sterilant. A reservoir assembly 130 is provided to allowcontinuous, uninterrupted flow of sterilant to vaporizer unit 300. Avaporizer feed line 192 is connected at one end to reservoir assembly130 and at another end to vaporizer unit 300.

Air conditioning unit 200 is provided to condition, i.e., to filter andto dry air used in vaporizer unit 300, and to filter air used byaeration unit 700. An air inlet conduit 212 has a first end thatcommunicates with the environment, namely room air, and another end thatis connected to air conditioning unit 200. A first air supply line 282is connected at one end to air conditioning unit 200 and at another endto vaporizer unit 300. A second air supply line 216 is connected at oneend to air conditioning unit 200 and at another end to aeration unit700.

As shown in FIG. 2, vaporizer unit 300 is connected to vaporizer feedline 192 from sterilant supply unit 100, and is connected to air line282 from air conditioning unit 200. Vaporizer unit 300 is comprised of ablower 322, a flow element 332 for measuring airflow, a heater 342 and avaporizer 360.

Blower 322 is disposed in air supply line 282 from air conditioning unit200. Blower 322 is driven by a motor 324. Motor 324 is preferably avariable speed motor, wherein the output of blower 322 can be controlledto increase or decrease air flow therethrough. When in operation, blower322 draws air through air conditioning unit 200 wherein the air is driedand filtered. In the embodiment shown, the outlet of blower 322 isconnected to a conduit 328. A flow element 332 is disposed withinconduit 328 to measure air flow through conduit 328. Flow element 332 ispreferably a Venturi device. A sensor 334 measures a pressure differenceacross flow element 332 and provides a signal indicative of the air flowthrough flow element 332. A Venturi device is preferable because of thehigh resolution of air flow it can provide and because of the low lossof power for the air flowing therethrough. A temperature sensor 338 isdisposed downstream from flow element 332.

Heater 342 is disposed within conduit 328 and is provided to heat theair flowing through conduit 328. Heater 342 is designed to be capable ofheating air flowing through conduit 328 up to a temperature high enoughto vaporize hydrogen peroxide and high enough to maintain a desiredtemperature sufficient to prevent condensation in sterilant supplysystem 10. In one embodiment, heater 342 is capable of heating airflowing through conduit 328 to at least about 105° C. In anotherembodiment, heater 342 is capable of heating air flowing through conduit328 to at least 180° C. A temperature sensor 344 is disposed downstreamof heater 342. Temperature sensor 344 provides a signal indicative ofthe temperature of the air flowing through conduit 328.

Vaporizer 360 is disposed within conduit 328 at a location downstreamfrom heater 342. A hydrogen peroxide vapor sensor 362, that provides asignal indicative of the concentration of hydrogen peroxide vapor andwater vapor, is disposed within conduit 328 on the outlet of vaporizer360. Sensor 362 is preferably an infrared (IR) sensor, and morepreferably a near infrared (IR) sensor.

A conduit 423 is connected at one end to a source (not shown) offiltered, dry pressurized air and at another end to vaporizer 360. Apump 426, driven by a motor 428, is disposed in sterilant supply line192 to feed sterilant under pressure into vaporizer 360. Pump 426 ispreferably a variable-speed peristaltic pump. Pump 426 is provided topump sterilant into vaporizer 360 at a selected rate. Motor 428 ispreferably a variable speed motor wherein the injection rate ofsterilant to vaporizer 360 can be varied by varying the speed of motor428. A pressure sensor 429 is disposed in sterilant supply line 192,downstream from pump 426. Pressure sensor 429 monitors (and ensures) aproper sterilant injection rate.

As illustrated in FIG. 2, conduit 328 divides into a first branch 328Aand a second branch 328B. Vaporizer unit 300 is connected todecontamination chambers 50A, 50B by hydrogen peroxide vapor branchconduits 328A, 328B. A first valve 364A is disposed in first branch 328Ato regulate the amount of flow through first branch 328A. A second valve364B is disposed in second branch 328B to regulate the amount of flowthrough second branch 328B.

A manifold 542 is mounted to an end of each hydrogen peroxide vaporbranch conduits 328A, 328B. Manifold 542 associated with first branch328A is essentially identical to manifold 542 associated with secondbranch 328B. Therefore, only manifold 542 associated with first branch328A will be described, it being understood that such descriptionapplies equally to manifold 542 associated with second branch 328B. Inthe embodiment shown, manifold 542 is disposed within housing 52.Manifold 542 has a plurality of spaced-apart openings or nozzles 544that communicate with space or region 54 in housing 52 ofdecontamination chamber 50A. Nozzles 544 are disposed above conveyor 14Ato distribute uniformly hydrogen peroxide vapor over containers 12moving through decontamination chamber 50A.

As shown in FIG. 1, conduits 612, 614 connect enclosure 52 ofdecontamination chamber 50A to destroyer unit 600. Conduit 612communicates with region 54 in enclosure 52 through a bottom ofenclosure 52. Conduit 614 communicates with region 54 in enclosure 52through one side of enclosure 52. An outlet conduit 618 fluidly connectsdestroyer unit 600 to a surrounding environment. Destroyer unit 600includes a destroyer. The destroyer is basically a catalytic device thatis operable to destroy hydrogen peroxide flowing therethrough. In thisrespect, catalytic destroyers convert the hydrogen peroxide vapor intowater and oxygen.

Referring now to FIG. 3, aeration unit 700 is best seen. Aeration unit700 is connected to second air supply line 216 from air conditioningunit 200. Second air supply line 216 from air conditioning unit 200supplies filtered air to aeration unit 700. Second air supply line 216is connected to the inlet side of a blower 712. Blower 712 is driven bya variable-speed motor 714. Blower 712 is disposed within aeration unit700 to draw air external to system 10 through air conditioning unit 200and through second air supply line 216. The outlet side of blower 712 isconnected to an aeration conduit 722. Aeration conduit 722 extendsthrough aeration unit 700. Downstream from blower 712, a flow element732 is disposed within aeration conduit 722. In a preferred embodiment,flow element 732 is a Venturi device.

A pressure sensor 734 measures the pressure difference across flowelement 732 to provide signals indicative of the flow through aerationconduit 722. A temperature sensor 736 is disposed before (upstream of)flow element 732. Temperature sensor 736 is disposed between blower 712and flow element 732. A valve 738 is disposed in aeration conduit 722downstream from flow element 732 to regulate the amount of flow throughaeration conduit 722. A filter 742 is disposed downstream from valve738. Filter 742, preferably a HEPA filter, provides a second filtrationof the air flowing through aeration conduit 722. A heater 744 isdisposed in aeration conduit 722 downstream from filter 742. Heater 744is provided to heat the air flowing along conduit 722.

As illustrated in FIG. 3, aeration conduit 722 divides into a firstbranch 722A and a second branch 722B. Aeration unit 700 is connected todecontamination chambers 50A, 50B by aeration branch conduits 722A,722B. A first valve 752A is disposed in first branch 722A to regulatethe amount of flow through first branch 722A. A second valve 752B isdisposed in second branch 722B to regulate the amount of flow throughsecond branch 722B.

A manifold 762 is connected to an end of each aeration branch conduits722A, 722B. Manifold 762 associated with first branch 722A isessentially identical to manifold 762 associated with second branch722B. Therefore, only manifold 762 associated with first branch 722Awill be described, it being understood that such description appliesequally to manifold 762 associated with second branch 722B. In theembodiment shown, manifold 762 is disposed in housing 52 ofdecontamination chamber 50A. Manifold 762 includes a plurality ofnozzles or ports 764 to distribute the filtered and heated air intodecontamination chamber 50A. Manifold 762 is disposed above conveyor 14Aat a location where conveyor 14A exits decontamination chamber 50A. Atemperature sensor 766 is disposed within manifold 762. Aeration unit700 basically provides heated, filtered air to decontamination chamber50A to purge hydrogen peroxide vapor from containers 12 on conveyor 14Aand to prevent condensation.

According to the present invention, a plurality of sensors are disposedwithin decontamination chambers 50A, 50B. The plurality of sensors areconnected to a controller 800 (described in detail below) to providesigns indicative of the operation of sterilant supply system 10 andconveyors 14A, 14B. The sensors associated with conveyor 14A areessentially identical to the sensors associated with conveyor 14B.Therefore, only the sensors associated with conveyor 14A will bedescribed, it being understood that such description applies equally tothe sensors associated with conveyor 14B.

As shown in FIG. 2, a temperature sensor 548 and a hydrogen peroxidevapor sensor 552 are disposed relative to conveyor 14A. In theembodiment shown, temperature sensor 548 and hydrogen peroxide vaporsensor 552 are disposed within manifold 542. Temperature sensor 548provides a signal indicative of the temperature within manifold 542.Hydrogen peroxide vapor sensor 552 provides a signal indicative of theconcentration of hydrogen peroxide vapor and water vapor in manifold542. Sensor 552 is preferably a near infrared (IR) sensor.

A conveyor sensor 562 is disposed relative to conveyor 14A. Conveyorsensor 562 provides a signal indicative of the movement of conveyor 14Athrough region 54. For example, conveyor sensor 562 may provide a signalindicative of the speed at which conveyor 14A is moving. In theembodiment shown, sensor 562 includes a wheel that is disposed to be incontact with conveyor 14A. In this respect, movement of conveyor 14Acauses the wheel to turn. As the wheel turns, sensor 562 provides asignal indicative of the movement of conveyor 14A. It is alsocontemplated that sensor 562 may be a conventionally known sensor, e.g.,a proximity sensor, that is useful at detecting movement of conveyor 14Athrough region 54.

An article sensor 564 is disposed relative to conveyor 14A. Articlesensor 564 provides a signal indicative of whether containers 12 aremoving through region 54. In the embodiment shown, sensor 564 is aconventional proximity sensor that is useful at detecting the presenceof an article at a predetermined location in region 54.

Controller 800 receives signals from the various sensors disposed withinsystem 10. In the embodiment shown, controller 800 receives signals froma plurality of sensors associated with sterilant supply system 10 andconveyors 14A, 14B. In particular, controller 800 receives signals fromsensors 334, 338, 344, 362, 429, 548, 552, 562, 564, 734, 736, 766.Controller 800 is programmed to monitor constantly the signals from theaforementioned sensors in order to control the operation of system 10and conveyors 14A, 14B and to determine if an event indicative of amalfunction has occurred with respect to system 10 or conveyors 14A,14B. If an event indicative of a malfunction is detected, controller 800is programmed to adjust the operation of system 10 and/or conveyors 14A,14B to maintain uninterrupted operation of as many processing lines aspossible. In particular, based upon the nature of the event detected bycontroller 800, controller 800 will shut down one or more processinglines and simultaneously adjust the operation of sterilant supply system10 and/or conveyors 14A, 14B in order to maintain uninterruptedoperation of as many processing lines as possible.

Events that are indicative of a malfunction include, but are not limitedto: 1) the speed that a processing line is conveying containers 12 isoutside of an acceptable speed range; 2) the number of containers 12that are conveyed along a processing line is outside of an anticipatedrange; 3) the concentration of hydrogen peroxide vapor that is conveyedto a processing line is outside of an acceptable range; 4) thetemperature of the air that is conveyed to a processing line is outsideof an acceptable range; 5) the flow rate of the hydrogen peroxide vaporthat is conveyed to a processing line is outside of an acceptable range.It is contemplated that other sensors may be placed within system 10 toprovide signals indicative of malfunctions other than those listedabove.

Controller 800 is programmed to control the air temperature, air flowrate, sterilant temperature and sterilant injection rate in sterilantsupply system 10 so that the concentration of hydrogen peroxide vaporconveyed to the first and second processing lines is within auser-defined acceptable range. Controller 800 also controls the speed atwhich containers 12 move along the first processing line and the secondprocessing line. In particular, controller 800 controls the speed thatcontainers 12 move so that the duration of time that containers 12 areexposed to hydrogen peroxide vapor is sufficient to sterilize containers12. Controller 800 includes input means for allowing a user to input theuser-defined acceptable range for the concentration of hydrogen peroxidevapor.

When using hydrogen peroxide vapor in a sterilization system, it isnecessary to prevent the hydrogen peroxide vapor from condensing on thearticles to be sterilized. In a steady state, steady flow hydrogenperoxide vapor sterilization process, the sterilant injection rate, theair flow rate and the air temperature must be controlled to preventcondensation. According to one embodiment of the present invention,system 10 is controlled to a desired hydrogen peroxide vaporconcentration and temperature, to prevent condensation. In particular,the operation of system 10 is controlled to maintain the concentrationof hydrogen peroxide vapor in an air stream at a dew point temperaturethat is below the temperature of articles to be sterilized. System 10may be controlled based upon a mathematical model, as described indetail in U.S. patent application Ser. No. 11/741,299.

Controller 800 is also programmed to control the air temperature and theair flow rate in aeration unit 700 so that the air conveyed to eachprocessing line is maintained within a user-defined acceptable flow raterange and within a user-defined acceptable temperature range. Controller800 includes input means for allowing a user to input the aforementioneduser-defined acceptable ranges.

Controller 800 receives signals from sensors 334, 338, 344, 362, 429,548, 552, 562, 564, 734, 736, 766. Controller 800 also controls theoperation of motors 16A, 16B, 324, 428, 714, valves 364A, 364B, 738,752A, 752B and heaters 342, 744. In particular, controller 800 controlsthe operation of the foregoing components based on signals received fromsensors 334, 338, 344, 362, 429, 548, 552, 562, 564, 734, 736, 766, asdescribed in detail below.

Referring now to the operation of the present invention, controller 800is programmed to cause system 10 to operate in two (2) different modesof operation, namely: (1) a first, normal mode of operation and (2) asecond, event-driven mode of operation. During the first mode ofoperation, all the processing lines are in full operation such thatcontainers 12 conveyed along the processing lines are sterilized. Duringthe second mode of operation, controller 800 adjusts the operation ofsystem 10 and/or conveyors 14A, 14B, as needed, in response to an eventthat is indicative of a malfunction with system 10 or conveyors 14A,14B.

During the first mode of operation, controller 800 controls system 10such that containers 12 conveyed along a plurality of processing linesare sterilized. In the embodiment shown, containers 12 are conveyedalong a first processing line, represented by conveyor 14A, and a secondprocessing line, represented by conveyor 14B. In particular, controller800 causes valves 364A, 36413 to be in an open position so that hydrogenperoxide vapor is conveyed from sterilant supply system 10 to containers12 moving along conveyors 14A, 14B.

As set forth above, controller 800 is programmed such that motors 16A,16B, 324, 428 and heater 342 are controlled based on signals receivedfrom sensors 334, 338, 344, 362, 429, 548, 552, 562, 564. In particular,based on the signals from sensor 552, controller 800 controls motor 428so that the quantity of liquid hydrogen peroxide supplied to vaporizer360 is sufficient to sterilize containers 12 moving throughdecontamination chambers 50A, 50B. Controller 800 also controls motor324 so that the quantity of air moving through vaporizer 360 issufficient to convey the hydrogen peroxide vapor to containers 12 movingthrough decontamination chambers 50A, 50B. Based on the signals fromtemperature sensor 548 in manifold 542, controller 800 controls heater342 to achieve the air temperature needed to maintain the concentrationof hydrogen peroxide vapor in each decontamination chamber 50A, 50Bwithin the user-defined acceptable range. Based on the concentration ofhydrogen peroxide vapor in decontamination chambers 50A, 50B, controller800 causes motors 16A, 16B to move containers 12 along the first andsecond processing lines at a speed that allows containers 12 to beexposed to hydrogen peroxide vapor for a duration of time sufficient tosterilize containers 12. As noted above, sensor 562 provides a signalindicative of the speed that conveyors 14A, 14B are moving containers12. Sensor 564 provides an indication of the number of containers 12that are moving along conveyors 14A, 14B. In this respect, based onsignals from sensors 562, 564, controller 800 determines whether thecorrect number of containers 12 are being conveyed throughdecontamination chambers 50A, 50B at the correct speed.

In one embodiment of the present invention, controller 800 also controlsthe air temperature and the air flow rate from aeration unit 700. Inthis respect, controller 800 controls aeration unit 700 so that the airconveyed to containers 12 moving through decontamination chambers 50A,50B is within the user-defined acceptable ranges. In this embodiment,controller 800 causes valves 752A, 752B to be in the open position sothat warm, sterile air is conveyed from aeration unit 700 to bothdecontamination chambers 50A, 50B. The warm, sterile air is provided toremove hydrogen peroxide vapor from containers 12 moving through bothdecontamination chambers 50A, 50B. In particular, based on signals fromsensors 736, 734, 766, controller 800 controls motor 714 and heater 744so that the quantity of air and the temperature of the air conveyed fromaeration unit 700 are sufficient to remove the hydrogen peroxide vaporfrom containers 12 moving through decontamination chambers 50A, 50B.

Residual hydrogen peroxide vapor exits decontamination chambers 50A, 50Bthrough conduits 612, 614. The residual hydrogen peroxide vapor isconveyed to destroyer unit 600 wherein the hydrogen peroxide vapor isreduced to water and oxygen. The water and oxygen are conveyed out ofdestroyer unit 600 through outlet conduit 618.

As described above, controller 800 thus causes system 10 to operate in afirst mode of operation wherein containers 12 moving along conveyors14A, 14B are sterilized.

During the first mode of operation, controller 800 constantly monitorsthe various sensors disposed within system 10 to determine if an eventindicative of a malfunction has occurred with respect to system 10 orconveyors 14A, 14B. For example, if the concentration of hydrogenperoxide vapor in one decontamination chamber drifts outside of theuser-defined acceptable range, sensor 552 will provide a signal tocontroller 800 that is indicative of such an event. Based on a detectedevent that is indicative of a malfunction, such as the one describedabove, controller 800 is programmed to initiate a second, event-drivenmode of operation. In general, during the second, event-driven mode ofoperation controller 800 adjusts the operation of system 10 and/orconveyors 14A, 14B so that as many processing lines as possible remainin operation.

The operation of the present invention with respect to the second modeof operation will be described in detail with respect to an eventindicative of a malfunction occurring along the first processing line,i.e., the processing line associated with conveyor 14A. However, it isunderstood that the following description would apply equally to thedetection of an event indicative of a malfunction occurring along thesecond processing line, i.e., the processing line associated withconveyor 14B.

Upon the detection of an event along the first processing line,controller 800 first determines whether the first processing line mustbe shut down or if the operation of the first processing line can be“modified” to maintain the first processing line in operation. Forexample, if the signal to controller 800 indicates that the flow ofsterilant vapor to the first processing line is stopped completely,controller 800 may determine that it is necessary to shut down the firstprocessing line. In this respect, controller 800 is programmed to causevalve 364A to move to a closed position such that decontaminationchamber 50A is isolated fluidly from vaporizer unit 300. Simultaneouslytherewith, controller 800 causes motor 16A to stop such that containers12 cease to move along conveyor 14A, i.e., the first processing line.

However, if the signal to controller 800 indicates that the sterilantvapor conveyed to chamber 50A is outside of the user-defined acceptablerange, controller 800 may determine that it is possible to “modify” theoperation of the first processing line to continue to sterilizecontainers 12 moving therealong. For example, if the flow of sterilantvapor to chamber 50A is low, controller 800 may cause motor 16A toreduce the speed that containers 12 move through chamber 50A so that theduration of time that containers 12 are in chamber 50A is sufficient tosterilize containers 12. If the flow of sterilant vapor to chamber 50Ais high, controller 800 may cause valve 364A to reduce the flow ofsterilant vapor to chamber 50A and/or controller 800 may cause motor 16Ato increase the speed that containers 12 move through chamber 50A. It isalso contemplated that controller 800 is programmed to modify theoperation of the first processing line if other parameters, such as thetemperature or the concentration of the sterilant vapor, are outside ofthe user-defined acceptable range.

Regardless of whether controller 800 shuts down the first processingline, or modifies the operation of the first processing line, controller800 will continue to monitor the sensors associated with the secondprocessing line. Based on the signals received from the sensorsassociated with the second processing line, controller 800 causes motors324, 428 to adjust the output of pump 426 and blower 322 so thatarticles conveyed along the second processing line, i.e., conveyor 14B,continue to be sterilized. For example, controller 800 is programmed touse the signals from sensor 552 in decontamination chamber 50B todetermine if the concentration of hydrogen peroxide vapor supplied todecontamination chamber 50B is within the user-defined acceptable range.If the concentration is outside of the user-defined acceptable range,controller 800 will cause motor 428 to decrease or increase the flowrate of liquid hydrogen peroxide to vaporizer 360. Similarly, controller800 will cause motor 324 to decrease or increase the flow rate of air todecontamination chamber 50B. Controller 800 will continue to adjustmotors 324, 428 until the concentration of hydrogen peroxide vapor indecontamination chamber 50B, as measured by sensor 552, is within theuser-defined acceptable range. Similarly, controller 800 is programmedto adjust motor 324 and heater 342 until the airflow rate and thetemperature of the air within decontamination chamber 50B is such thatthe concentration of hydrogen peroxide vapor in decontamination chamber50B is within the user-defined acceptable range. Controller 800 is alsoprogrammed to adjust the speed of motor 16B such that containers 12 areexposed to hydrogen peroxide vapor for a duration of time sufficient tosterilize containers 12.

It is contemplated that controller 800 also may initiate the second modeof operation based upon an event indicative of a malfunction of conveyor14A. In this respect, the event indicative of a malfunction may be asignal from sensor 564 that indicates that containers 12 have ceased tomove through decontamination chamber 50A. Similarly, the eventindicative of a malfunction may be a signal from sensor 562 thatindicates that the speed of conveyor 14A is outside of an acceptablerange. Based on the aforementioned signals, controller 800 is programmedto initiate the second mode of operation, as described above.

Controller 800 is also programmed to initiate the second mode ofoperation based upon a signal received from an operator. For example, anoperator may send a signal to controller 800 that indicates that thefirst processing line is to be shut down. The command from the operatormay be in response to a malfunction detected by the operator or becausethe operator wishes to perform maintenance on the first processing line.In either respect, based on the signal from the operator, controller 800will initiate the second mode of operation to shut down the firstprocessing line.

Regardless of the reasons the second mode of operation was initiated,controller 800 will continue to cause system 10 to operate in the secondmode of operation until it is determined that the first processing lineis ready to resume full operation. The operator then will send a signalto controller 800 to place the first processing line back into fulloperation. Based on the signal from the operator, controller 800 willcause valve 364A to move to the appropriate position and motor 16A tocause conveyor 14A to convey containers 12 through decontaminationchamber 50A at the appropriate speed. Simultaneously therewith,controller 800 will control the components of vaporizer unit 300 tomaintain the concentration of hydrogen peroxide vapor in bothdecontamination chambers 50A, 50B within the user-defined acceptablerange. For example, controller 800 is programmed to cause motor 428 toincrease or decrease the flow rate of liquid hydrogen peroxide tovaporizer 360 and to cause motor 324 to increase or decrease the flowrate of air to decontamination chambers 50A, 50B. Controller 800 willcontinue to adjust motors 324, 428 until the concentration of hydrogenperoxide vapor in decontamination chambers 50A, 50B is within theuser-defined acceptable range. Similarly, controller 800 is programmedto adjust heater 342 until the air temperature in both decontaminationchambers 50A, 50B is such that concentration of hydrogen peroxide vaporin each decontamination chamber is within the user-defined, acceptablerange. As noted above, the speed at which containers 12 move along thefirst processing line is determined based on the concentration ofhydrogen peroxide vapor in decontamination chamber 50A. The speed ofcontainers 12 is selected to expose containers 12 to hydrogen peroxidevapor for a duration of time sufficient to sterilize containers 12.

According to another embodiment of the present invention, controller 800is programmed to cause aeration unit 700 to stop or adjust the flow ofair to the processing line associated with decontamination chamber 50A,during the second mode of operation. In this respect, controller 800 isprogrammed to adjust the position of valve 752A, as needed.Simultaneously therewith, controller 800 monitors sensors 734, 736, 766in system 10. Based on the signals received from the foregoing sensors,controller 800 will control motor 714 to adjust the output of blower 712so that the amount of air conveyed into decontamination chamber 50Bremains within the user-defined acceptable range. For example,controller 800 is programmed such that, based on signals from sensor 766in manifold 762, controller 800 determines if the temperature of the airsupplied to decontamination chamber 50B is within the user-definedacceptable range. If the temperature of the air is outside of theuser-defined acceptable range, controller 800 will increase or decreasethe amount of heat generated by heater 744 to raise or lower thetemperature of the air conveyed through decontamination chamber 50B.Similarly, controller 800 will adjust motor 714 until the amount of airflowing through decontamination chamber 50B is within the user-definedacceptable range.

The operation of system 10 during the second mode of operation wasdescribed above in reference to shutting down or modifying the operationof the first processing line. Similarly, controller 800 is programmed toshutdown or to modify the operation of the second processing line, whilemaintaining the first processing line in full operation.

System 10 has been described heretofore in reference to a system withtwo (2) processing lines. It is contemplated that system 10 may includemore than two (2) processing lines wherein each processing line isconnected to sterilant supply system 10. In this embodiment, controller800 is programmed to monitor continuously a plurality of sensorsassociated with system 10. If an event indicative of a malfunction isdetected with respect to one or more of the plurality of processinglines, controller 800 is programmed to adjust the operation of system 10to maintain as many processing lines in full operation as possible. Forexample, based on the detected event, controller 800 may shut down oneor more processing lines while maintaining uninterrupted operation ofthe remaining processing lines.

The foregoing description is a specific embodiment of the presentinvention. It should be appreciated that this embodiment is describedfor purposes of illustration only, and that numerous alterations andmodifications may be practiced by those skilled in the art withoutdeparting from the spirit and scope of the invention. It is intendedthat all such modifications and alterations be included insofar as theycome within the scope of the invention as claimed or the equivalentsthereof.

Having described the invention, the following is claimed:
 1. A systemfor conveying a sterilant vapor to a plurality of processing lineshaving articles moving therealong, said system comprised of: a singlevaporizer unit for supplying a sterilant vapor; conveying means forconveying said sterilant vapor from said single vaporizer unit to aplurality of processing lines; sensing means for sensing a plurality ofoperational parameters associated with said system and said plurality ofprocessing lines; and a controller for receiving signals from saidsensing means, said controller programmed to operate in a first mode,wherein said controller monitors continuously said sensing means todetermine if an event indicative of a malfunction has occurred withrespect to said system or said plurality of processing lines, and saidcontroller programmed to operate in a second mode in response to saidevent, wherein said controller adjusts the operation of said system tomaintain uninterrupted operation of one or more of said plurality ofprocessing lines.
 2. A system as defined in claim 1, wherein saidcontroller is programmed to adjust the output of said central source inresponse to said event.
 3. A system as defined in claim 2, wherein saidcontroller is programmed to adjust the concentration of said sterilantvapor supplied by said single vaporizer unit in response to said event.4. A system as defined in claim 2, wherein said controller is programmedto adjust the temperature of said sterilant vapor supplied by saidsingle vaporizer unit in response to said event.
 5. A system as definedin claim 2, wherein said controller is programmed to adjust the flowrate of said sterilant vapor supplied by said single vaporizer unit inresponse to said event.
 6. A system as defined in claim 1, wherein saidcontroller is programmed to adjust selectively the concentration of saidsterilant vapor supplied to each of said plurality of processing linesin response to said event.
 7. A system as defined in claim 1, whereinsaid controller is programmed to adjust selectively the temperature ofsaid sterilant vapor supplied to each of said plurality of processinglines in response to said event.
 8. A system as defined in claim 1,wherein said controller is programmed to adjust selectively the flowrate of sterilant vapor supplied to each of said plurality of processinglines in response to said event.
 9. A system as defined in claim 1,wherein said controller is programmed to adjust the operation of saidplurality of processing lines in response to said event.
 10. A system asdefined in claim 9, wherein said controller is programmed to adjust thespeed of said plurality of processing lines in response to said event.11. A system as defined in claim 1, wherein said sensing means includes:one conveyor sensor associated with one of said plurality of processinglines, said conveyor sensor operable to provide a signal indicative ofthe speed of said processing line associated with said conveyor sensor.12. A system as defined in claim 11, wherein said event indicative of amalfunction with said system is a signal from said conveyor sensor thatindicates that the speed at which said articles move along said one ofsaid plurality of processing lines is outside of a user-definedacceptable range.
 13. A system as defined in claim 1, wherein saidsensing means includes: one article sensor associated with one of saidplurality of processing lines, said article sensor operable to provide asignal indicative of the presence of an article at a predeterminedlocation along said processing line associated with said article sensor.14. A system as defined in claim 13, wherein said event indicative of amalfunction with said system is a signal from said article sensor thatindicates that the number of said articles moving along said one of saidplurality of processing lines is outside of a user-defined acceptablerange.
 15. A system as defined in claim 1, wherein said sensing meansincludes: one sterilant sensor associated with one of said plurality ofprocessing lines, said sterilant sensor operable to provide a signalindicative of the concentration of said sterilant vapor at a discretelocation along said processing line associated with said sterilantsensor.
 16. A system as defined in claim 15, wherein said eventindicative of a malfunction with said system is a signal from saidsterilant sensor that indicates that the concentration of said sterilantvapor at said discrete location is outside of a user-defined acceptablerange.
 17. A system as defined in claim 1, wherein said sensing meansincludes: one temperature sensor associated with one of said pluralityof processing lines, said temperature sensor operable to provide asignal indicative of the temperature of said sterilant vapor at adiscrete location along said processing line associated with saidtemperature sensor.
 18. A system as defined in claim 17, wherein saidevent indicative of a malfunction with said system is a signal from saidtemperature sensor that indicates that the temperature of said sterilantvapor at said discrete location is outside of a user-defined acceptablerange.
 19. A system as defined in claim 1, wherein said sensing meansincludes: one flow rate sensor associated with one of said plurality ofprocessing lines, said flow rate sensor operable to provide a signalindicative of the flow rate of said sterilant vapor at a discretelocation along said processing line associated with said flow ratesensor.
 20. A system as defined in claim 19, wherein said eventindicative of a malfunction with said system is a signal from said flowrate sensor that indicates that the flow rate of said sterilant vapor atsaid discrete location is outside of a user-defined acceptable range.21. A system as defined in claim 1, wherein said single vaporizer unitincludes: a vaporizer connected to a sterilant supply unit for supplyinguninterrupted flow of a liquid sterilant, said vaporizer for vaporizingsaid liquid sterilant; and a first blower for conveying said sterilantvapor to a discrete location along each of said plurality of processlines.
 22. A system as defined in claim 1, wherein said system furtherincludes: a plurality of conduits wherein each of said conduits extendsfrom said single vaporizer unit to one of said plurality of processinglines, and a valve disposed within each of said plurality of conduitsfor allowing said controller to independently control the flow of saidsterilant vapor from said single vaporizer unit to each of saidplurality of processing lines.